advanced high-strength steel technologies in the 2014 chevy silverado
Post on 18-Jan-2016
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2014 Chevrolet Silverado/GMC Sierra Body 1500 Cab Structure Review
Thomas Grabowski General Motors
Company
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Vehicle IntroductionChevrolet Silverado
Silverados exterior design blends strong Chevy truck heritage with a refined, modern aesthetic
Hauling goods since 1918
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Vehicle Introduction GMC Sierra
GMC designers approached the exterior with respect for its predecessors, evolving its familiar shape while adding distinctive details
A century of truck production
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High-level Changes From Current Truck
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2013 rear door opening
Improved Noise and Vibration performance New inset door design Triple seal system, reduced wind noise
2014 rear door opening
High-level Changes From Current Truck
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High-level Changes From Current Truck
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Anticipated Segment Firsts
Direct Injection, Active Fuel Management, and Variable Valve Timing powertrains are standard across the lineup
The first Direct Injected V-8 in a light duty pickup
5.3L V-8 EcoTec3 AFM VVT DI
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Anticipated Segment Firsts
Standard projector headlamps on
GMC Sierra
Standard DuraLife brake rotors
Forward Collision Alert /Lane Departure Warning /Safety Alert Seat
Real aluminum interior trim
Ultrasonic front park assist
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All New Cargo Box Innovations
CornerStep rear bumper
Moveable cargo box upper tie-downs
LED under-rail box lighting
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Three Available Cab Configurations
Regular Cab 8 box shown 66 available
Double Cab 66 box shown
Crew Cab 58 box shown 66 available
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Redesigned Interior: Silverado Shown
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All New 8 Color Touch Screen Option
Redesigned interior: hand stitched panels, touch
screen
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Redesigned Seating: Sierra Shown
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Interior Functionality: Silverado Shown
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Cab Structure Development: Introduction
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Cab Structure Development: Agenda
1. Body in White Objectives 2. Vehicle durability 3. Material selection 4. Part commonality 5. Safety structure 6. Mass reduction strategies 7. Noise/Vibration management
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Objectives of the Body in White Design
Performance goals of the BIW: Outstanding performance on all
governmental and consumer safety metrics.
Enhanced overall stiffness for handling and Noise/Vibration performance.
Mass Reduction without compromising Durability.
Manufacturing goal Drive part commonality to enable production in three assembly plants.
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Vehicle Durability Video
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Vehicle Durability Video
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Material Selection Upper Structures Mild Steel
Bake Hardenable
HSLA
Dual-Phase/Multi-Phase
Press Hardened Steel
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Material Selection Lower Structures Mild Steel
Bake Hardenable
HSLA
Dual-Phase/Multi-Phase
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6%
24%
19% 23%
28%
Material Breakdown by part count
Material Selection Extensive Use Of Press Hardened Steel
Mild Steel
Bake Hardenable
HSLA
Dual-Phase/Multi-Phase
Press Hardened Steel
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Manufacturing Footprint
Flint Asm, Michigan Crew Cab Regular Cab
Fort Wayne Asm, Indiana Double Cab Regular Cab
Silao Asm, Mexico Crew Cab Regular Cab
2012 Silverado and Sierra total sales volume: 575,497
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Part Commonality Across Three Cab Configurations Common on all Cabs
Common Double and Crew Cab
Unique to Crew Cab
Common door hardware system
Flexible assembly tooling
Reduces investment, piece cost
51% 25%
24% Crew Cab commonality breakdown by part count
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Part Commonality Across Three Cab Configurations
Common Press Hardened Steel die tooling
Dual cavity tooling reduces investment
Higher volumes decrease piece cost
Dual cavity tool
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Load Vector
Reinforcement Safety Cage U.S. Roof strength:
IIHS Two Sided (FMVSS 216A)
Loads are carried by: Front roof header #2 Roof bow PHS roof rail outer Center pillar assembly with shear plate
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Load Vector
Side Impact: IIHS Side NCAP FMVSS 214
Reinforcement Safety Cage
Side impact loads are dissipated through: PHS center pillar assembly Rocker outer assembly PHS roof rail assembly #2 PHS roof bow
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Safety Cage Key Reinforcements
Dual Phase welded tube reinforcement
Dual Phase rocker reinforcement
Arc brazed shear plate
Press Hardened Steel pillar reinforcement
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Reinforcement Safety Cage Center Pillar Asm
Arc brazed Low Alloy shear plate
Press Hardened Steel pillar reinforcement asm
Consistent geometry in load path, initiator free
Shear plate offsets smaller cross section
Arc brazing reduces B&R weld flange stack-up
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Reinforcement Safety Cage Rocker Asm
High-Frequency Induction weld joint
Dual Phase welded tube reinforcement
Resistance weld joint
High-frequency induction welding, enables a design specific tube reinforcement
Resistance welded to rocker reinforcement
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Mass Reduction Strategies Roll Forming
HSLA 0.95mm
HSLA 1.2mm
Roll formed platform for lower mass and higher cargo capability
Minimizes thinning for increased durability
Roll formed cross sills
Pickup Box
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Mass Reduction Strategies Tailor Welded Blank
Dual Phase 1.2mm
Dual Phase 0.8mm
Gage reduction outside of load path
Enables current assembly process
Joint avoidance in load sensitive area
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Mass Reduction Strategies Tailor Welded Blank
Door inner
Rear door Blank
Mild Steel 0.75mm
Bake Hardenable 1.6mm
R100
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Mass Reduction Strategies Part Consolidation
Reference Design
Optimized Design
Dual Phase reinforcement
Dual Phase reinforcement
Mild steel mounting plate reinforcement
Design for Six Sigma project enabled an integrated sun visor attachment related to FMVSS 201 execution
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Mass Reduction Strategies Part Boundary Reduction
Reference Design
Optimized Design
Material upgrade enabled
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Mass Reduction Strategies Scallop Flange Utilization
General Motors Global Best Practice
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Mass Reduction Strategies Torsional Optimization
View inside cab
Welded corner bracket provided a 4% increase in torsion performance
Enable the removal of a less efficient reinforcement.
Created down gaging opportunity's on surrounding panels
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Noise/Vibration Management Body Mount Development
Change to shear-style body mount insulator
50% increase in local structure stiffness required
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Noise & Vibration Management Sealing Strategy Body sealer
Structural adhesive
Optimized body joints to enable robust sealing
103% increase in structural adhesive
44% reduction in airborne noise paths.
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Noise & Vibration Management Shape Optimization
Design for Six Sigma methodology applied to developed bead shapes resulting in reduced back panel vibration.
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Noise/Vibration Management Body Stiffness
Bending Mode
Torsional Mode
Torsional Mode
17% increase in Global Torsional performance
10% increase in Global Bending
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Summary Ultra High Strength Steel stampings enabled a significant
increase in safety performance with mass efficiency
Part commonization strategy reduced tooling investment
Optimized part geometry enables mass efficiency
The 2014 Silverado/Sierra weighs 110 lb less on average than its major competitor
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THANK YOU Thomas Grabowski Design Release Engineer General Motors Company
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Great Designs in Steel is Sponsored by:
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PRESENTATIONS WILL BE AVAILABLE MAY 3
Slide Number 1Slide Number 2Vehicle Introduction GMC Sierra High-level Changes From Current Truck High-level Changes From Current Truck High-level Changes From Current TruckAnticipated Segment FirstsAnticipated Segment FirstsAll New Cargo Box InnovationsThree Available Cab ConfigurationsRedesigned Interior: Silverado ShownAll New 8 Color Touch Screen OptionRedesigned Seating: Sierra Shown Interior Functionality: Silverado ShownCab Structure Development: Introduction Cab Structure Development: AgendaObjectives of the Body in White DesignSlide Number 18Slide Number 19Material Selection Upper StructuresMaterial Selection Lower StructuresSlide Number 22Manufacturing FootprintPart Commonality Across Three Cab ConfigurationsPart Commonality Across Three Cab ConfigurationsSlide Number 26Slide Number 27Slide Number 28Slide Number 29Slide Number 30Slide Number 31Slide Number 32Slide Number 33Slide Number 34Slide Number 35Slide Number 36Slide Number 37Noise/Vibration Management Body Mount DevelopmentNoise & Vibration Management Sealing StrategyNoise & Vibration Management Shape OptimizationNoise/Vibration Management Body StiffnessSummarySlide Number 43Slide Number 44
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